Mixing tube and method of manufacturing the mixing tube

This application claims the benefit of Japanese Application 2003-22098, filed Jan. 30, 2003, and Japanese Application 2003-383664, filed Nov. 13, 2003, the entireties of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a mixing tube and to a method of manufacturing the mixing tube. In particular, the present invention relates to a technique which can be suitably employed for a mixing tube used for mixing two types of fluids during production of a two-component reactive adhesive such as an epoxy adhesive, a polyurethane adhesive, or a silicon adhesive, or a sealant or a packing material.

2. Description of the Related Art

A two-component adhesive consists of base and catalyst agents which are prepared separately, and the base and catalyst agents are mixed together in use. Conventionally, the base and catalyst agents are mixed by employing a manual method using a knife, a spatula, or the like, a method that utilizes a dispenser using a static mixer, or a method that uses a specially designed mixer.

However, the following problems exist when performing mixing of materials by using the conventional methods. Hardening of the base agent and the catalyst agent in a two-component adhesive begins upon mixing of the base agent with the catalyst agent, and curing occurs even at room temperature. Therefore, there are occasions where the materials adhere to the knife, the spatula, inner portions of the static mixer, and containers within the specially designed mixer after one time usage. Therefore, the whole mixture cannot be used for its original purpose as an adhesive, resulting in disposal of the cured material.

Further, the degree of mixing performed by an operator depends on the judgement of the operator, and there is a problem in that differences develop in the quality of the resultant mixtures.

In view of the above-mentioned problems, the applicant of the present invention has already invented a mixing tube for mixing multi-component materials. This mixing tube manufactured from a flexible material, such as, a plastic film or the like, wherein a residual material, after mixing tube materials, remained inside the mixing tube can be squeezed out by squeezed the mixing tube. In this prior invention, plural containers that separately receive multi-component materials are provided to the mixing tube, and the multi-component materials are discharged from the plural containers. The features of the mixing tube are as follows. The mixing tube has an inlet port for mounting there to the containers that receive multi-component materials, a mixing passage for mixing multi-component materials that are injected from the inlet port, and an outlet port discharging the multi-component materials which have been mixed in the mixing passage. By continuously squeezing the mixing passage from the inlet port toward the outlet port of the mixing passage, the multi-component materials injected from the inlet port pass through the mixing passage to be mixed, and then are discharged from the outlet port (refer to JP 2003-001078 A).

The mixing passage of the mixing tube may be configured, for example, by connecting plural passage blocks in series, the passage blocks having the same number of deformed passages as the number of the materials to be mixed, and by suitably connecting the outlet port and the inlet port of each of the deformed passages at the connection portions of the passage blocks in order to repeat the operation of dividing the materials to be mixed that are discharged from a prior stage passage block at the inlet port to a subsequent stage passage block, and aggregating materials to be mixed at the outlet port. If the number of passage block connections is taken as N, the materials to be mixed are divided 2^Ntimes, and thus allowing sufficient mixing.

However, the configuration of the conventional mixing tube, with which the materials to be mixed are theoretically mixed 2^Ntimes, is complex. The configuration is difficult to reproduce, and difficult to manufacture. This type of mixing tube is therefore expensive and not suited to mass production.

SUMMARY OF THE INVENTION

The present invention is made in view of the above-described problems. An object of the present invention is to provide a mixing tube tat has a relatively simple structure, and that is capable of dividing, aggregating, and sufficiently mixing multi-component materials. This mixing tube is manufactured from a flexible material, such as; a plastic film or the like, wherein a residual material; that remains inside the mixing tube after mixing tube materials can be squeezed out by saueezing the mixing tube.

In order to solve the above-mentioned technical problems, a mixing tube according to the present invention has the following structure. The mixing tube includes a first mixing passage and a second mixing passage for mixing the materials to be mixed, and causes multi-component materials to pass through the first mixing passage and the second mixing passage, repeatedly dividing and aggregating the materials tote mixed by passing them though the mixing passages. The first mixing passage and the second mixing passage are formed by a first outer frame member, a second outer frame member, and a partition member that is interposed between the first and second outer frame members, the three members dividing the mixing tube in a direction toward which the materials to be mixed pass, and holes are formed at fixed intervals in the partition member in a direction of mixing which the materials. The first mixing passage and the second mixing passage repeatedly divide and aggregate the materials due to the holes, thereby the materials are divided and aggregated repeatedly.

With the above described structure, the materials to be mixed pass through the first and the second mixing passages, and through the holes of the partition member, and the materials are divided and aggregated, to thereby to be mixed sufficiently. The mixing tube is configured by three members including the first outer frame member, the second outer frame member, and the partition member, and they can be configured and assembled easily and simply. Further, there are no limitations to the sectional shapes of the first and the second outer frame members, and the shapes may be rectangular, circular, rhombic, or the like. That is, there are no limitations to the sectional shapes so long as the plurality of mixing passages formed in the mixing tube repeatedly divide and merge together the materials to be mixed through the partition member having the holes.

One method of using the mixing tube according to the present invention is, for example, to squeeze the mixing tube manually by hand or the like, thus squeezing out the materials to be mixed. Accordingly, materials having flexibility and that are capable of being squeezed with a predetermined force are suitable for the mixing tube material. According to the mixing tube, the materials to be mixed in within the mixing tube pass through the mixing passages by continuing to manually squeeze the mixing tube by hand from the inlet ports to the outlet ports side of the first and the second mixing passages, thereby sufficient mixing can be performed. Further, the materials to be mixed within the mixing tube can be substantially completely squeezed out by fully squeezing the mixing tube to tips of the outlet ports of the mixing passages.

Furthermore, the first mixing passage and the second mixing passage of the mixing tube according to the present invention have a plurality of elements whose sectional shapes change continuously, and that are connected in series. The holes of the partition member are formed to have a size that is equal to half the length of each of the elements in the direction of mixing the materials.

According to the above described structure, a compressive force and a shear force are continuously applied to the materials to be mixed as they pass through each of the elements having the sectional shape that changes continuously. Further, the holes, each having a size equal to half the length of each of the elements, are formed in the partition member, and therefore the materials to be mixed that pass through each of the deformed passages arc regularly divided and merged together. That is, the materials to be mixed continuously receive compressive forces and shear forces as they pass through the mixing passages, and in addition, the materials to be mixed are regularly divided and merged together with the materials to be mixed that pass through other mixing passages. The mixing passages thus mix the multi-component materials uniformly.

In addition, it is desirable that the mixing tube according to the present invention further includes flange portions provided in joining portions where the first outer frame member, the second outer frame member, and the partition member are joined, wherein the flange portions being formed along, and outside of, the first mixing passage and the second mixing passage, in which the flange portion of the partition member is sandwiched between the flange portions of the first outer frame member and the second outer frame member, thus integrating the first outer frame member, the second outer frame member, and the partition member and forming the first mixing passage and the second mixing passage.

According to the above-described configuration, the first outer frame member, the second outer frame member, and the partition member can easily be integrated. That is, it becomes possible to easily form the first and the second mixing passages, which are capable of sufficiently mixing the materials to be mixed, by using a relatively simple configuration.

Furthermore, it is desirable that the mixing tube according to the present invention includes intermediate partitions provided in the first outer frame member and the second outer frame member, for dividing the first mixing passage and the second mixing passage, in which the intermediate partitions of the first outer frame member and the second outer frame member are welded in the holes of the partition member.

The first mixing passage and the second mixing passage can each be divided by providing the intermediate partitions described above. An operation can be repeated by which the materials to be mixed, having been discharged from the elements, are divided at the inlet ports of the subsequent elements, and then merged together at the outlet ports of the elements. According to this mixing tube, if the number of elements connected is taken as N, then the materials to be mixed are divided 2^Ntimes, thereby to be possible to perform sufficient mixing. Further, a complete intermediate partitions are formed by welding the intermediate partitions of the first outer frame member and the intermediate partitions of the second outer frame member. It thus becomes possible to form the complete intermediate partitions at the same time will forming the first mixing passage and the second mixing passage. An example of the configuration of the intermediate partitions may be such that the cross sections in the longitudinal direction of the first outer frame member and the second outer frame member are formed in a substantially “M” shape. In addition, it is preferable that the intermediate partitions be formed perpendicular to the partition member that are interposed between the first outer frame member and the second outer frame member, and that the intermediate partitions be disposed in the center of the partition member. It becomes possible to reliably divide the first and the second mixing passages into two sections by thus forming the intermediate partition portions.

The mixing tube according to the present invention may have intermediate partitions provided in the first outer frame member and the second outer frame member for dividing the first mixing passage and the second mixing passage respectively, and the intermediate partitions of the first outer frame member and the second outer frame member are each welded to the partition member.

The intermediate partitions may also be formed in a state of dividing the first mixing passage and the second mixing passage, respectively, by welding the intermediate partitions of the first outer frame member and the intermediate partitions of the second outer frame member to the partition member. Accordingly, an operation can be repeated by which the materials to be mixed, which have been discharged from the elements, are divided at the inlet ports to the subsequent elements and then merged together at the outlet ports of the elements. If the number of elements connected are taken as N, then the materials to be mixed are divided 2^Ntimes by the mixing tube, and it becomes possible to perform sufficient mixing.

Furthermore, it is preferable that the mixing tube according to the present invention includes joining portions provided in the holes of the partition member, the joining portions are contact with the intermediate partitions of the first outer frame member and the second outer frame member, wherein the joining portions are welded to the intermediate partitions of the first outer frame member and the second outer frame member.

By forming the joining portions described above, the intermediate partitions of the first outer frame member and the second outer frame member are reliably fixed to the partition member. It becomes possible to form the intermediate partitions in a state where the first mixing passage and the second mixing passage are divided. Further, the intermediate partitions of the first outer frame member and the intermediate partitions of the second outer frame member can each be fixed to the joining portions. It therefore becomes possible to use various types of manufacturing methods.

A method of manufacturing a mixing tube according to the present invention comprises: molding a first outer frame member and a second outer frame member that are made out of a thermoplastic resin; forming holes in a partition member that is made out of a thermoplastic resin; welding end portions of flanges of the partition member, the first outer frame member, and the second outer frame member, while the flanges of the first outer frame member and the second outer frame member sandwiching the flanges of the partition member, thus integrating the first outer frame member, the second outer frame member, and the partition member, and forming a first mixing passage and a second mixing passage.

According to the configuration described above, it is possible to form the mixing passages by welding the flanges, causing them to adhere together, whereby it is thus possible to easily manufacture the mixing tube. Furthermore, the term of thermoplastic resin denotes substances that soften and melt when heated, and harden when cooled. Serene resins, acrylic resins, cellulose resins, polyethylene resins, vinyl resins, nylon resins, fluorocarbon resins, and the like may be given as examples of thermoplastic resins.

Methods of welding a thermoplastic resin are explained here. The methods can be roughly divided as follows: a high frequency welding where an object to be heated is made to emit heat by itself due to electric potential movement at a molecular or electron level according to a high frequency electrolytic action of several tens of megahertz; an ultrasonic welding where ultrasonic vibrations at ultrasonic energy having a frequency equal to or greater than 20 kHz are transmitted to an object to be heated from a resonator referred to as a horn, thus generating strong frictional heating and welding the object; and a thermal welding where the object to be welded is heated by thermal conduction from a heat source located outside of the object to be heated. In addition, a convection welding, a hot plate welding, an impulse welding, and welding by using an iron can be given as examples of the thermal welding. Any type of welding method may be used by the present invention, so long as the method can weld the first outer frame member, the second outer frame member, and the partition member.

In addition, it is preferable that in the method of manufacturing a mixing tube according to the present invention, the first outer frame member and the second outer frame member are molded, while forming intermediate partitions that divide the first mixing passage and the second mixing passage, and the intermediate partitions and the partition member are welded, or the intermediate partitions are welded together. A mixing tube in which the first mixing passage and the second mixing passage are each divided can be formed by melt bonding the intermediate partitions and the partition member, or by welding the intermediate partitions together. Further, the welding of the intermediate partitions can be performed at the time of welding of the first outer frame member, the second outer frame member, and the partition member, and therefore manufacturing can be performed efficiently.

Furthermore, the method of manufacturing a mixing tube according to the present invention comprises: molding a first outer frame member and a second outer frame member that are made out of a thermoplastic resin, while forming intermediate partitions for dividing a first mixing passage and a second mixing passage; forming holes in partition members that are made out of a thermoplastic resin while forming joining portions that are contact with the intermediate partitions of the first outer frame member and the second outer frame member; a first step of welding flanges of the first outer frame member and flanges of the partition member; a second step of welding flanges of the second outer frame member and flanges of the partition member; and a third step of welding flanges of the members manufactured in the first step and the second step. According to this manufacturing method, the partition members are welded to the first outer frame member and the second outer frame member. Adhering the first outer member and the partition member, and adhering the second outer member and the partition member, are then welded to the flanges. That is, manufacturing can be divided up and performed in separate steps compared to a manufacturing method in which the three types of members are welded at the same time. It therefore becomes possible to perform each of the manufacturing steps with ease.

In addition, the method of manufacturing a mixing tube according to the present invention comprises: molding a first outer frame member and a second outer frame member that are made out of a thermoplastic, resin while forming intermediate partitions for dividing a first mixing passage and a second mixing passage; forming holes in partition members that are made out of a thermoplastic resin, while forming joining portions that are in contact with the intermediate partitions of the first outer frame member and the second outer frame member; a first step of welding flanges of the first outer frame member and flanges of the partition member, and welding the intermediate partitions of the first outer frame member and the joining portions of the partition member; a second step of welding flanges of the second outer frame member and flanges of the partition member, and welding the intermediate partitions of the second outer frame member and the joining portions of the partition member; and a third step of welding flanges of the members manufactured in the first step and the second step. According to this manufacturing method as well, the partition members are welded to the first outer frame member and the second outer frame member. Adhering first outer frame member and partition member, and adhering second outer frame member and partition member, are then welded to the flanges. That is, manufacturing can be divided up and performed in separate steps compared to a manufacturing method in which the three types of members are welded at the same time. It therefore becomes possible to perform each of the manufacturing steps with ease.

In addition, a member that is connected to container containing the materials to be mixed, and a jig for adjusting the shape of the materials to be mixed that are injected and discharged, may also be manufactured with the present invention at the same time as welding of the flanges is performed. Operations for injecting and discharging the materials to be mixed can be performed easily if, for example, a jig that widens the width for easy injection of the materials to be mixed, and a jig that throttles the materials to be mixed in order to discharge the materials to an appropriate location, are provided in an inlet port and an outlet port, respectively, of the mixing tube.

A mixing tube that divides and merges together the materials to be mixed, thereby sufficiently mixing the materials to be mixed, can thus be provided by using a relatively simple structure according to the present invention. Furthermore, because the structure is a simple one, it becomes possible to easily perform mass production of the mixing tubes, which has conventionally been difficult.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings:

<figref idref="DRAWINGS">FIG. 1</figref> is a plan view of a mixing tube according to an embodiment mode of the present invention;

<figref idref="DRAWINGS">FIG. 2</figref> is a sectional diagram of the mixing tube according to the embodiment mode of the present invention, taken along a line X-X′;

<figref idref="DRAWINGS">FIG. 3</figref> is a plan view in which the mixing tube according to the embodiment mode of the present invention is exploded into a first outer frame member, a second outer frame member, and a partition member;

<figref idref="DRAWINGS">FIG. 4</figref> is a perspective view that shows a first passage block and a second passage block of the mixing tube according to the embodiment mode of the present invention;

<figref idref="DRAWINGS">FIGS. 5A to 5E</figref> are diagrams explaining mixing states of the first passage block of the mixing tube according to the embodiment mode of the present invention;

<figref idref="DRAWINGS">FIG. 6</figref> is a diagram explaining a method of using the mixing tube according to the embodiment mode of the present invention;

<figref idref="DRAWINGS">FIG. 7</figref> is a diagram explaining a method of using the mixing tube according to the embodiment mode of the present invention;

<figref idref="DRAWINGS">FIG. 8</figref> is a plan view of a mixing tube according to a first embodiment;

<figref idref="DRAWINGS">FIG. 9</figref> is a plan view in which the mixing tube according to the first embodiment is exploded into a first outer frame member, a second outer frame member, and a partition member;

<figref idref="DRAWINGS">FIG. 10</figref> is a perspective view that shows a first passage block and a second passage block of the mixing tube according to the first embodiment;

<figref idref="DRAWINGS">FIGS. 11A to 11E</figref> are diagrams explaining mixing states of the first passage block of the mixing tube according to the first embodiment; and

<figref idref="DRAWINGS">FIG. 12</figref> is a plan view in which a mixing tube according to a second embodiment is exploded into a first outer frame member, a second outer frame member, and partition members.

DETAILED DESCRIPTION OF THE INVENTION

An embodiment mode of a mixing tube according to the present invention, and a method of manufacturing the mixing tube, will be described in detail below with reference to the drawing.

<figref idref="DRAWINGS">FIG. 1</figref> is a plan view of a mixing tube <b>10</b> according to this embodiment mode, and <figref idref="DRAWINGS">FIG. 2</figref> is a sectional view of the mixing tube <b>10</b> shown in <figref idref="DRAWINGS">FIG. 1</figref>, taken along a line X-X′. Two types of materials A and B having fluidity to be mixed are separately contained in plural containers <b>40</b>A and <b>40</b>B, which are mounted at one end of the mixing tube <b>10</b>. The mixing tube is a tube for mixing the materials A and B to be mixed that are pushed out from the containers <b>40</b>A and <b>40</b>B containing materials to be mixed. The mixing tube <b>10</b> is formed of a soft thermoplastic resin which can be squeezed over its entirety with a predetermined force.

Further, the mixing tube <b>10</b> consists of two types of passage blocks, first passage blocks <b>11</b> and second passage blocks <b>12</b>, connected alternately and in series. An injection port <b>18</b> that communicates with the containers <b>40</b>A and <b>40</b>B containing materials to be mixed, and that injects the materials A and B to be mixed into deformed passages of the mixing tube <b>10</b>, is provided to one of the first passage blocks <b>11</b> at one end of the series connection. A discharge port <b>19</b>, through which the materials A and B to be mixed having been mixed are discharged, is provided to one of the second passage blocks <b>12</b> at the other end of the series connection.

Further, the containers materials <b>40</b>A and <b>40</b>B containing to be mixed have connection portions <b>41</b>A and <b>41</b>B for connection with the injection port <b>18</b> of the mixing tube <b>10</b>.

Deformed passages <b>13</b> and <b>14</b> for mixing, and deformed passages <b>16</b> and <b>17</b> for mixing, are formed inside the first passage blocks <b>11</b> and the second passage blocks <b>12</b>, respectively. The deformed passages are formed by a partition member <b>15</b> that is disposed vertically between a first outer frame member <b>21</b> and a second outer frame member <b>22</b> in a direction toward which the materials to be mixed pass through. <figref idref="DRAWINGS">FIG. 3</figref> is a plan view of the mixing tube <b>10</b> exploded into the first outer frame member <b>21</b>, the second outer frame member <b>22</b>, and the partition member <b>15</b>.

The first outer frame member <b>21</b> has voids where the deformed passages <b>13</b> of the first passage blocks <b>11</b> and the deformed passages <b>16</b> of the second passage blocks <b>12</b> are formed. Flanges <b>21</b><i>a </i>are provided in the first outer frame member <b>21</b> at both ends in the longitudinal direction thereof in order to be welded to the second outer frame member <b>22</b> and the partition member <b>15</b>. Further, the second outer frame member <b>22</b> has voids where the deformed passages <b>14</b> of the first passage blocks <b>11</b> and the deformed passages <b>17</b> of the second passage blocks <b>12</b> are formed. Flanges <b>22</b><i>a </i>are provided in the second outer frame member <b>22</b> at both ends in the longitudinal direction thereof in order to be welded to the first outer frame member <b>21</b> and the partition member <b>15</b>. Holes <b>15</b><i>c</i>, each having the same size as one another and each of which is half the size of each of the passage blocks, are formed at fixed intervals in the partition member <b>15</b>. As shown, each holes <b>15</b><i>c </i>has a polygonal outer perpheral shape. Flanges <b>15</b><i>a </i>are provided in the partition member <b>15</b> at both ends in the longitudinal direction thereof in order to be welded to the first outer frame member <b>21</b> and the second outer frame member <b>22</b>.

Further, <figref idref="DRAWINGS">FIG. 4</figref> is a perspective view in which the first passage block and the second passage block of the mixing tube are exploded into each of the deformed passages. The deformed passages <b>13</b> and <b>14</b> of the first passage block <b>11</b> have rectangular inlet ports <b>13</b><i>b </i>and <b>14</b><i>b</i>, respectively, whose longer sides are in an X direction. One square is formed by overlapping and joining the inlet ports <b>13</b><i>b </i>and <b>14</b><i>b</i>. Further, an outlet port <b>11</b><i>b </i>has a square shape, and the holes <b>15</b><i>c </i>are formed in the partition member <b>15</b> between the two passages, thus forming one outlet port <b>11</b><i>b. </i>

The deformed passages <b>13</b> and <b>14</b> have sectional shapes and sectional areas that continuously change from an inlet point P<b>1</b> toward an outlet point P<b>5</b>. The deformed passages <b>13</b> and <b>14</b> respectively take on a shorter sided square shape at an intermediate point P<b>3</b> between the inlet point P<b>1</b> and the outlet point P<b>5</b> (refer to <figref idref="DRAWINGS">FIGS. 5A to 5E</figref>) compared with the side lengths at the inlet point. Further, the partition member <b>15</b> is disposed between the deformed passages <b>13</b> and <b>14</b> from the inlet point P<b>1</b> to the intermediate point P<b>3</b>, dividing the deformed passages <b>13</b> and <b>14</b> into two portions. However, the holes <b>15</b><i>c </i>are formed in the partition member <b>15</b> between the deformed passages <b>13</b> and <b>14</b> from the intermediate point P<b>3</b> to the outlet point P<b>5</b>. Further, the deformed passages <b>13</b> and <b>14</b> are each divided in half from the intermediate point P<b>3</b> to the outlet point P<b>5</b> and one of the deformed passages <b>13</b><i>d </i>and <b>14</b><i>d </i>has an inclined surface. The sectional areas of the deformed passages <b>13</b> and <b>14</b> become gradually larger from the intermediate point P<b>3</b> to the outlet point P<b>5</b>. That is, the two deformed passages <b>13</b> and <b>14</b> gradually merge from the intermediate point P<b>3</b> toward the outlet point P<b>5</b>, and become one square shape passage at the outlet port <b>11</b><i>b. </i>

Next, the second passage block <b>12</b> has the deformed passages <b>16</b> and <b>17</b>. The deformed passages <b>16</b> and <b>17</b> are disposed opposite to the deformed passages <b>13</b> and <b>14</b> of the first passage block. The outlet port <b>11</b><i>b </i>of the deformed passages <b>13</b> and <b>14</b> in the first passage block <b>11</b> at upstream side thus communicates with the inlet ports <b>16</b><i>b </i>and <b>17</b><i>b </i>of the deformed passages <b>16</b> and <b>17</b> in the second passage block at downstream side, at a portion that connects the first passage block <b>11</b> and the second passage block <b>12</b>.

The materials A and B to be mixed that are mixed in the first passage block <b>11</b> are then divided in half at the inlet ports <b>16</b><i>b </i>and <b>17</b><i>b </i>of the deformed passages <b>16</b> and <b>17</b> of the second passage block <b>12</b>. The materials A and B to be mixed are mixed in each of the deformed passages <b>16</b> and <b>17</b> from an inlet point Q<b>1</b> to an intermediate point Q<b>3</b>. Further, the holes <b>15</b><i>c </i>are formed in the partition member <b>15</b> between the intermediate point Q<b>3</b> and an outlet point Q<b>5</b> in the second passage block <b>12</b>, similar to the first passage block <b>11</b>. In addition, the deformed passages <b>16</b> and <b>17</b> are each divided in half and respective deformed passages <b>16</b><i>d </i>and <b>17</b><i>d </i>have inclined surfaces. The materials A and B to be mixed, which are mixed in each of the deformed passages <b>16</b> and <b>17</b> between the intermediate point Q<b>3</b> and the outlet port point Q<b>5</b>, thus merge and mix. Repeating the procedure of mixing and dividing allows the materials A and B to be mixed to be uniformly mixed.

Mixing states of the materials A and B to be mixed, when passing through the first passage block <b>11</b> and the second passage block <b>12</b> that are connected in series will be explained next. States where the materials A and B to be mixed pass through the first passage block <b>11</b> are shown in <figref idref="DRAWINGS">FIGS. 5A to 5E</figref>. Note that the reference symbols P<b>1</b> to P<b>5</b> in <figref idref="DRAWINGS">FIGS. 5A to 5E</figref> correspond to material passage positions of the first passage block <b>11</b> in <figref idref="DRAWINGS">FIG. 4</figref>, and are sectional views in the material passage positions as seen from the inlet ports. Further, the reference symbols A and B denote the materials to be mixed.

As shown in <figref idref="DRAWINGS">FIG. 5(</figref><i>a</i>), the materials A and B to be mixed that are injected into the first passage blocks <b>11</b> from the containers <b>40</b>A and <b>40</b>B containing for materials to be mixed, are divided into two rectangular portions whose longer sides are in the X direction at the inlet point P<b>1</b>. Then, the lengths of the rectangular portions in the X direction gradually become shorter as shown in ETG. <b>5</b> (<i>b</i>), and the deformed passages <b>13</b> and <b>14</b> for the materials A and B to be mixed change into a square shape at the intermediate point P<b>3</b> as shown in <figref idref="DRAWINGS">FIG. 5(</figref><i>c</i>). The deformed passages <b>13</b> and <b>14</b> thereafter gradually merge because the holes <b>15</b><i>c </i>are formed in the partition member <b>15</b> between the deformed passages <b>13</b> and <b>14</b>, as described above. The materials A and B to be mixed therefore merge together as shown in <figref idref="DRAWINGS">FIG. 5(</figref><i>d</i>). The deformed passages <b>13</b> and <b>14</b> are completely merged at the outlet point P<b>5</b>, and the materials A and B to be mixed exist in a mutually mixed state at the outlet point P<b>5</b>, as shown in <figref idref="DRAWINGS">FIG. 5(</figref><i>e</i>).

The materials A and B to be mixed that have been mixed by the first passage block <b>11</b> are then divided into two rectangular portions whose longer sides are in the X direction at the inlet port of the second passage block <b>12</b>. The two types of the materials A and B to be mixed thus substantially merge and are divided. The larger the number of stages of the first passage block <b>11</b> and the second passage block <b>12</b>, the greater the number of times that the materials A and B to be mixed are divided and merge together. The degree of mixing therefore becomes higher as the number of stages increases.

That is, the mixing tube <b>10</b> forms layers at a theoretical value of 2^N. Accordingly, the materials A and B, to be mixed can be sufficiently mixed. Furthermore, it is possible to create an agitating effect by generating a plug flow developing from a strong wall surface resistance against the materials A and B to be mixed.

A method of manufacturing the mixing tube <b>10</b> will be explained next. First, the first outer frame member <b>21</b>, the second outer frame member <b>22</b>, and the partition member <b>15</b> are formed. The first outer frame member <b>21</b> and the second outer frame member <b>22</b> are each formed by vacuum formation in a shape having voids that become the deformed passages <b>13</b> and <b>14</b> of the passage block <b>11</b>, and the deformed passages <b>16</b> and <b>17</b> of the passage block <b>12</b>, respectively. The term of vacuum formation denotes a formation method in which a planar sheet plate is vacuum aspirated into a metal heated mold to be deformed. Note that although each of the members is formed by vacuum formation in this embodiment mode, there are no limitations to the formation method. Various other formation methods can also be used, so long as they are formation methods which can form in desired shapes and the like.

The partition member <b>15</b> is in a sheet-like shape, and provided with holes <b>15</b><i>c</i>, each having a size corresponding to half the size of the passage block <b>11</b> or the passage block <b>12</b> of the mixing tube <b>10</b>. At this point, flanges <b>21</b><i>a</i>, <b>22</b><i>a </i>and <b>15</b><i>a </i>are formed in the first outer frame member <b>21</b>, the second outer frame member <b>22</b>, and the partition member <b>15</b>, respectively, at both ends in the longitudinal direction of the respective members. The flanges <b>21</b><i>a </i>and <b>22</b><i>a </i>of the first outer frame member <b>21</b> and the second outer frame member <b>22</b>, respectively, sandwich the flange <b>15</b><i>a </i>of the partition member <b>15</b>. The ends of the flanges <b>21</b><i>a</i>, <b>22</b><i>a </i>and <b>15</b><i>a </i>of the respective three members are then welded together. The mixing tube <b>10</b> according to this embodiment mode can thus be manufactured.

A method of using the mixing tube <b>10</b> will be explained next. In the case where the materials A and B to be mixed by using the mixing tube <b>10</b>, the connection portions <b>41</b>A and <b>41</b>B of the two containers <b>40</b>A and <b>40</b>B for materials to be mixed, respectively, are each connected to the injection port <b>18</b> of the mixing tube <b>10</b>, as shown in <figref idref="DRAWINGS">FIG. 1</figref>.

Next, the materials A and B to be mixed that are contained in the two containers <b>40</b>A and <b>40</b>B are squeezed out by continuously squeezing each of the two containers <b>40</b>A and <b>40</b>B from a rear side to a front side. The containers for materials <b>40</b>A and <b>40</b>B containing to be mixed are made from vinyl, silicon, or similar material that is capable of being squeezed with a predetermined force, and therefore the squeezing operation may be performed manually by hand. A jig such as a tube squeezer may also be used. The materials A and B to be mixed thus squeezed out are then each injected from the injection port <b>18</b> of the mixing tube <b>10</b> to the deformed passages <b>13</b> and <b>14</b> of the first passage block <b>11</b> of a first stage.

Thus injected into the first passage block <b>11</b>, the materials A and B to be mixed are then squeezed out from the discharge port <b>19</b> by continuously squeezing the mixing tube <b>10</b> from the inlet port toward the outlet port.

Dividing and merging together of the materials A and B to be mixed are repeatedly performed by means of the deformed passages <b>13</b> and <b>14</b> of the first passage block <b>11</b>, and the deformed passages <b>16</b> and <b>17</b> of the second passage block <b>12</b> at this point as described above. Each of the deformed passages <b>13</b>, <b>14</b>, <b>16</b>, and <b>17</b> is squeezed, and localized shear forces thus act on the materials A and B to be mixed. Consequently, mixing is sufficiently performed.

Further, the materials A and B to be mixed in the mixing tube <b>10</b> can be completely squeezed out by fully squeezing the tube to the tip of the end of the discharge port <b>19</b> thereof, as shown in <figref idref="DRAWINGS">FIG. 7</figref>. Residue of materials within the mixing tube <b>10</b> can thus be eliminated.

As described above, the mixing tube <b>10</b> of the present invention is formed by using a material capable of being squeezed manually by hand with a predetermined force. Accordingly, the materials A and B to be mixed in the mixing tube <b>10</b> can be substantially completely squeezed out in a mixed state by continuously squeezing the mixing tube <b>10</b> from the inlet port side toward the outlet port side.

It should be noted that, although the mixing tube is squeezed by hand in this embodiment mode, it becomes possible to efficiently mix the materials to be mixed if a jig or similar device is used, provided that the jig or similar device is capable of sandwiching the mixing tube from both side surfaces, continuously squeezing the mixing tube.

Embodiment 1

A first embodiment will be explained next, based on the drawings, wherein a mixing tube <b>30</b> is provided with intermediate partitions at which the deformed passages <b>13</b> and <b>14</b> of the first passage blocks <b>11</b>, and the deformed passages <b>16</b> and <b>17</b> of the second passage blocks <b>12</b>, respectively, of the mixing tube <b>10</b> are each divided. <figref idref="DRAWINGS">FIG. 8</figref> is a plan view of the mixing tube <b>30</b> according to the first embodiment. The mixing tube <b>30</b> is a tube that mixes the two types of materials A and B to be mixed having fluidity, similar to the mixing tube described above. The mixing tube <b>30</b> is an embodiment in which the shapes of the deformed passages <b>13</b>, <b>14</b>, <b>16</b> and <b>17</b> of the mixing tube <b>10</b> are modified. Other structures are similar to those of the mixing tube <b>10</b>, and therefore explanations of such structures are omitted here.

The mixing of tube <b>30</b> consists of two types of passage blocks of first passage blocks <b>31</b> and second passage blocks <b>32</b>, connected alternately and in series. Deformed passages <b>61</b>, <b>62</b>, <b>63</b> and <b>64</b> that are used for mixing, and deformed passages <b>65</b>, <b>66</b>, <b>67</b> and <b>68</b> that are used for mixing, are formed in the first passage blocks <b>31</b> and the second passage blocks <b>32</b>, respectively. The deformed passages are formed by the intermediate partitions formed in a partition member <b>35</b> that is interposed between a first outer frame member <b>51</b> and a second outer frame member <b>52</b> that divide the mixing tube <b>30</b> vertically in a direction through which the materials to be mixed pass. And by intermediate partitions <b>51</b><i>b </i>and <b>51</b><i>c</i>, and <b>52</b><i>b </i>and <b>52</b><i>c </i>formed in the first outer frame member <b>51</b> and the second outer frame member <b>52</b>. <figref idref="DRAWINGS">FIG. 9</figref> is a plan view in which the mixing tube <b>30</b> is exploded into the first outer frame member <b>51</b>, the second outer frame member <b>52</b>, and the partition member <b>35</b>.

The first outer frame member <b>51</b> has voids where the deformed passages <b>61</b> and <b>62</b> of the first passage blocks <b>31</b> and the deformed passages <b>65</b> and <b>66</b> of the second passage blocks <b>32</b> are formed. Flanges <b>51</b><i>a </i>for welding and adhering to the second outer frame member <b>52</b> and the partition member <b>35</b> are provided in the first outer frame member <b>51</b> at both ends in the longitudinal direction thereof. The intermediate partitions <b>51</b><i>b </i>are provided in the first outer frame member <b>51</b> to divide the first passage block <b>31</b> into the two deformed passages <b>61</b> and <b>62</b>. The intermediate partitions <b>51</b><i>b </i>are formed by benting the first outer frame member <b>51</b> so as to divide the first passage blocks <b>31</b>. The sectional shape of the first outer frame member <b>51</b> at a location where the intermediate partitions <b>51</b><i>b </i>are provided has a substantially “M” shape. Further, the intermediate partitions <b>51</b><i>b</i>, each has a length that is half the length of the first passage block <b>31</b>. The materials to be mixed can thus be divided into two portions and discharged from the first passage blocks <b>31</b> to the adjacent second passage blocks <b>32</b>. In addition, the intermediate partitions <b>51</b><i>c </i>are provided in the first outer frame member <b>51</b>, dividing the second passage blocks <b>32</b> into the two deformed passages <b>65</b> and <b>66</b>.

The second outer frame member <b>52</b> has voids where the deformed passages <b>63</b> and <b>64</b> of the first passage blocks <b>31</b> and the deformed passages <b>67</b> and <b>68</b> of the second passage blocks <b>32</b> are formed. Flanges <b>52</b><i>a </i>for welding and adhering to the first outer frame member <b>51</b> and the partition member <b>35</b> are provided in the second outer frame member <b>52</b> at both ends in the longitudinal direction thereof. Further, the intermediate partitions <b>52</b><i>b </i>and <b>52</b><i>c </i>are formed in order to divide the second outer frame member <b>52</b> into the deformed passages, similar to the first outer frame member <b>51</b>. The holes <b>35</b><i>c</i>, each having a size corresponding to half the size of each of the passage blocks are formed at a fixed spacing in the partition member <b>35</b>. Flanges <b>35</b><i>a </i>for welding and adhering to the first outer frame member <b>51</b> and the second outer frame member <b>52</b> are formed in the partition member <b>35</b> at both sides in the longitudinal direction thereof.

<figref idref="DRAWINGS">FIG. 10</figref> is a perspective view in which the first passage block <b>31</b> and the second passage block <b>32</b> are exploded into separate deformed passages. An inlet port <b>31</b><i>a </i>of the first passage block <b>31</b> has a square shape, and is formed by the rectangular deformed passages <b>61</b> and <b>63</b> whose longer sides are in the X direction overlap. Further, an outlet port <b>31</b><i>b </i>of the first passage block also has a square shape, and is formed by four deformed passages <b>61</b>, <b>62</b>, <b>63</b> and <b>64</b>. The holes <b>35</b><i>c </i>are formed in the partition member <b>35</b> that is disposed between two of the passages in the outlet port <b>31</b><i>b</i>. The four deformed passages therefore each communicate with an adjacent deformed passage in a Y direction. That is, the deformed passage <b>62</b> and the deformed passage <b>63</b> communicate, and the deformed passage <b>61</b> and the deformed passage <b>64</b> communicate, thus forming rectangular passages whose longer sides are in the Y direction.

The sectional shape and the sectional area of the deformed passages <b>61</b> and <b>63</b> that form the inlet port <b>31</b><i>a </i>change continuously from an inlet point R<b>1</b> toward an outlet point R<b>5</b>. The deformed passages <b>61</b> and <b>63</b> take on short sided square shapes at an intermediate point R<b>3</b>, and maintain the same shapes until reaching the outlet port. The intermediate partitions <b>51</b><i>b </i>and <b>52</b><i>b </i>are formed in the first outer frame member <b>51</b> and in the second outer frame member <b>52</b>, respectively, from the intermediate point R<b>3</b> to the outlet point R<b>5</b>. The deformed passages <b>62</b> and <b>64</b> are formed adjacent to the deformed passages <b>61</b> and <b>63</b> from the intermediate point R<b>3</b> to the outlet point R<b>5</b>. The deformed passages <b>62</b> and <b>64</b> have inclined surfaces, and the sectional area of each of the inclined surfaces gradually becomes larger from the intermediate point R<b>3</b> toward the outlet point R<b>5</b>. Further, the holes <b>35</b><i>c </i>are formed in the partition member <b>35</b> from the intermediate point R<b>3</b> to the outlet point R<b>5</b>. The deformed passages <b>62</b> and <b>63</b> are adjacent in the Y direction, and therefore, merge at the outlet port, and the deformed passages <b>61</b> and <b>64</b> that are adjacent in the Y direction merge at the outlet port.

Next, the second passage blocks <b>32</b> have the deformed passages <b>65</b>, <b>66</b>, <b>67</b> and <b>68</b>. The deformed passages of the first outer frame member and the second outer frame member of the first passage blocks <b>31</b> are inverted around the Y direction. At connection between the first passage block <b>31</b> and the second passage block <b>32</b>, the deformed passages <b>61</b> and <b>62</b> of the first passage block <b>31</b> on upstream side communicate with the deformed passage <b>65</b> of the second passage block <b>32</b> on downstream side. The deformed passages <b>63</b> and <b>64</b> of the first passage block <b>31</b> communicate with the deformed passage <b>67</b> of the second passage block <b>32</b>.

According to the mixing tube <b>30</b> thus configured, the materials A and B to be mixed that are mixed in the first passage block <b>31</b> are then divided in half in the deformed passages <b>65</b> and <b>67</b> of the second passage block <b>32</b>. The materials A and B to be mixed are mixed within the deformed passages <b>65</b> and <b>67</b> from an inlet point S<b>1</b> to an intermediate point S<b>3</b>. From the intermediate point S<b>3</b> to an outlet point S<b>5</b>, the deformed passage <b>65</b> and the deformed passage <b>68</b> merge at the outlet port, and the deformed passage <b>67</b> and the deformed passage <b>66</b> merge at the outlet port. The materials A and B to be mixed are thus mixed. Repeating the dividing procedure allows uniform mixing of the materials A and B to be mixed.

Mixing states when the materials A and B to be mixed pass through the first passage blocks <b>31</b> and the second passage blocks <b>32</b> that are connected in series will be explained next. States where the materials A and B to be mixed pass through the first passage block <b>31</b> are shown in <figref idref="DRAWINGS">FIGS. 11(</figref><i>a</i>) to <b>11</b>(<i>e</i>). Note that the reference symbols R<b>1</b> to R<b>5</b> in <figref idref="DRAWINGS">FIGS. 11(</figref><i>a</i>) to <b>11</b>(<i>e</i>) correspond to material passage positions of the first passage block <b>31</b> in <figref idref="DRAWINGS">FIG. 10</figref>, and are sectional views in the material passage positions as seen from the inlet port. Further, the reference symbols A and B denote the materials to be mixed.

The materials A and B to be mixed that are injected into the first passage block <b>31</b> from the containers <b>40</b>A and <b>40</b>B containing materials to be mixed are divided into two deformed passages <b>61</b> and <b>63</b> each having a rectangular shape with longer sides are in the X direction at the inlet point R<b>1</b>, as shown in <figref idref="DRAWINGS">FIG. 11(</figref><i>a</i>). The lengths in the X direction then gradually become shorter as shown in <figref idref="DRAWINGS">FIG. 11(</figref><i>b</i>), and the deformed passages <b>61</b> and <b>63</b> for the materials A and B to be mixed change into a square shape at the intermediate point R<b>3</b> as shown in <figref idref="DRAWINGS">FIG. 11(</figref><i>c</i>). Thereafter, the deformed passages <b>61</b> and <b>64</b>, and the deformed passages <b>62</b> and <b>63</b> gradually merge, respectively. The materials A and B to be mixed merge together as shown in <figref idref="DRAWINGS">FIG. 11(</figref><i>d</i>). At the outlet point P<b>5</b>, the deformed passages <b>61</b> and <b>64</b>, and the deformed passages <b>62</b> and <b>63</b>, form the rectangular outlet ports <b>31</b><i>b </i>tat are long in the Y direction, as shown in <figref idref="DRAWINGS">FIG. 11(</figref><i>c</i>).

The materials A and B to be mixed that have been mixed by the first passage block <b>31</b> are then divided into two deformed passages <b>65</b> and <b>67</b> each having a rectangular shape with longer sides in the X direction at the inlet port <b>32</b><i>a </i>of the second passage block <b>32</b>. The two types of the materials A and B to be mixed thus substantially merge together and are divided. The larger the number of stages of the first passage block <b>31</b> and the second passage block <b>32</b>, the greater the number of times that the materials A and B to be mixed are divided and merge together. The degree of mixing therefore becomes higher as the number of stages increases. That is, the mixing tube <b>30</b> forms layers at a theoretical value of 2^N. Accordingly, the materials A and B to be mixed can be sufficiently mixed.

A method of manufacturing the mixing tube <b>30</b> will be explained next. First, the first outer frame member <b>51</b>, the second outer frame member <b>52</b>, and the partition member <b>35</b> are formed. The first outer frame member <b>51</b> and the second outer frame member <b>52</b> are configured such that the deformed passages of the first passage blocks <b>31</b> and the second passage blocks <b>32</b> are formed while forming the respective intermediate partitions <b>51</b><i>b</i>, <b>51</b><i>c</i>, <b>52</b><i>b </i>and <b>52</b><i>c</i>. The partition member <b>35</b> has a sheet-like shape, and the holes <b>35</b><i>c </i>each having a size that is half the length of each passage block <b>31</b> or each passage block <b>32</b> of the mixing tube <b>30</b> are formed. At this time flanges <b>51</b><i>a</i>, <b>52</b><i>a </i>and <b>35</b><i>a </i>are formed in the first outer frame member <b>51</b>, the second outer frame member <b>52</b>, and the partition member <b>35</b>, respectively, at both ends in the longitudinal direction of the respective members. The ends of the flanges <b>51</b><i>a</i>, <b>52</b><i>a </i>and <b>35</b><i>a </i>of the respective three members are then welded together, the flanges <b>51</b><i>a </i>and <b>52</b><i>a </i>of the first outer frame member <b>51</b> and the second outer frame member <b>52</b>, respectively, sandwiching the flanges <b>35</b><i>a </i>of the partition member <b>35</b>. The intermediate partitions <b>51</b><i>b </i>and <b>51</b><i>c </i>of the first outer frame member <b>51</b>, and the intermediate partitions <b>52</b><i>b </i>and <b>52</b><i>c </i>of the second outer frame member are also welded together. The mixing rube <b>30</b> according to the first embodiment can thus be manufactured.

Embodiment 2

Another embodiment of a mixing tube will be explained based on the according drawings in which joining portions <b>35</b><i>d </i>are provided in the partition member <b>35</b> of the mixing tube <b>30</b>, the joining potions contacting the intermediate partitions <b>51</b><i>b </i>and <b>51</b><i>c </i>of the first outer frame member <b>51</b> and the intermediate partitions <b>52</b><i>b </i>and <b>52</b><i>c </i>of the second outer frame member <b>52</b>. The mixing tube according to the second embodiment differs from the mixing tube <b>30</b> according to the first embodiment only in the shape of the partition member <b>35</b> and the method of manufacturing the partition member <b>35</b>. The external shape and other structures of the completed mixing tube are similar to those of the mixing tube <b>30</b>. Reference symbols similar to those of the first embodiment are therefore used here, and explanations of such portions are omitted.

<figref idref="DRAWINGS">FIG. 12</figref> is a plan view in which the mixing tube according to the second embodiment is explained into the first outer frame member <b>51</b>, the second outer frame member <b>52</b>, and the partition members <b>35</b>. In the first embodiment, there is only one partition member <b>35</b>, but in the second embodiment, there are two partition members <b>35</b>. The joining portions <b>35</b><i>d </i>that contact the intermediate partitions <b>51</b><i>b </i>and <b>51</b><i>c </i>of the first outer frame member <b>51</b> and the intermediate partitions <b>52</b><i>b </i>and <b>52</b><i>c </i>of the second outer frame member <b>52</b> are provided in each of the holes <b>35</b><i>c </i>of the partition members <b>35</b>.

A method of manufacturing the mixing tube will be explained next. First, the first outer frame member <b>51</b>, the second outer frame member <b>52</b>, and the two partition members <b>35</b> are formed. The first outer frame member <b>51</b> and the second outer frame member <b>52</b> are configured such that the deformed passages of the first passage blocks <b>31</b> and the second passage blocks <b>32</b> are formed while forming the respective intermediate partitions <b>51</b><i>b</i>, <b>51</b><i>c</i>, <b>52</b><i>b</i>, and <b>52</b><i>c</i>. The partition members <b>35</b> have a sheet-like shape. The holes <b>35</b><i>c </i>each having a size that is half the length of each passage block <b>31</b> or each passage block <b>32</b> of the mixing tube <b>30</b> are formed while leaving the joining portions <b>35</b><i>d </i>that contact the intermediate partitions <b>51</b><i>b</i>, <b>51</b><i>c</i>, <b>52</b><i>b </i>and <b>52</b><i>c</i>. At this time the flanges <b>51</b><i>a</i>, <b>52</b><i>a </i>and <b>35</b><i>a </i>are formed in the first outer frame member <b>51</b>, the second outer frame member <b>52</b>, and the partition members <b>35</b>, respectively, at both ends in the longitudinal direction of the respective members. The flanges <b>35</b><i>a </i>of the first outer frame member <b>51</b> and the flanges <b>35</b><i>a </i>of one of the two partition members <b>35</b> are then welded. Further, the flanges <b>35</b><i>a </i>of the other partition member <b>35</b> and the flanges <b>52</b><i>a </i>of the second outer frame member <b>52</b> are welded. The adhering outer first frame member <b>51</b> and the one partition member <b>35</b>, and the adhering second outer frame member <b>52</b> and the other partition member <b>35</b>, are then welded. The mixing tube can thus be manufactured while forming the intermediate partitions that divide each of the deformed passages. It should be noted that only the flanges <b>51</b><i>a</i>, <b>52</b><i>a</i>, and <b>35</b><i>a </i>of the first outer frame member <b>51</b>, the second outer frame member <b>52</b>, and the partition members <b>35</b>, respectively, are welded to one another in the second embodiment. However, the intermediate partitions <b>51</b><i>b</i>, <b>51</b><i>c</i>, <b>52</b><i>b</i>, and <b>52</b><i>c</i>, and the joining portions <b>35</b><i>d </i>of the partition members <b>35</b> may also be welded in addition to welding of the flanges <b>51</b><i>a</i>, <b>52</b><i>a</i>, and <b>35</b><i>a</i>, in the second embodiment.

It should be noted that the sectional areas and the sectional shapes of the first passage block and the second passage block all change continuously in this embodiment. However, the mixing tubes <b>10</b> and <b>30</b> according to the present invention are not limited to this configuration. A configuration may also be adopted in which only the sectional shapes or the sectional areas change continuously, thus allowing compressive and shear forces to act on the materials to be mixed that pass through the mixing tube.